生产件批准程序PPAP概述

1、生产件批准程序生产件批准程序 Production Part Approval Process (PPAP) Presented by: Max Zhang Ford CSO STA 9th August 2007PPAP is to demonstrate suppliers understanding of:PPAP是为表明供应商怎样理解以下内容的一个过程：是为表明供应商怎样理解以下内容的一个过程：零件的功能Parts functionality零件的特性Parts Characteristics特性的关键性Criticality of features 怎样测量零件How to gaug

2、e the part生产要求Production requirementsApplication什么时候用到什么时候用到PPAP? PPAP is required for, but not limited to: PPAP对以下情况适用（但不局限于）： All new tooled parts （使用新模具生产零件）All new vehicle programs and running changes for vehicles currently in production (新车型，或者是对现有车型的变更)Any change in supplier operating pattern

3、(i.e. new shift) (生产模式的变更)Any additional, modified or reconfigured production tooling, equipment or work streams （模具，设备或生产线的增加，改造或重新装配）Revised customer DPV (Daily Production Volume) exceeding verified supplier capacity level （客户需求量的增加）Content内容内容Phased PPAP introduction阶段性生产件批准程序的介绍Ford special requ

4、irements to PPAP 18 elements.福特汽车对于生产件批准18个项目的要求。VPP usageVPP的使用方法阶段性生产件批准程序阶段性生产件批准程序PHASED PPAP PROCESSWhat is the Phased PPAP?什么是什么是Phased PPAP？Phased PPAP is Fords approach to PPAP process management Phased PPAP是福特特有的生产件批准管理程序。Introduced to improve upon launch performance 用来提高项目开发和实施的表现。Requires

5、 a supplier site to demonstrateManufacturing capability （制造能力）Product quality （产品质量）And production capacity （产能）prior to job #1 （在J#1之前）Phased PPAP vs the old PPAPPhased PPAP与与PPAP的比较的比较 Phased PPAP organizes the process into four phases Phase 0: Run-at-Rate Phase 1: Quality Verification Phase 2: Pr

6、oduction Verification Phase 3: Capacity VerificationPPAPX1 PPFEUJob 1Phased PPAPPhase 0Phase 1Phase 2Phase 3Supplier Phased PPAP Process Map阶段性生产件批准程序示意图阶段性生产件批准程序示意图STATUS:Phase 2Completed Phase 2 Warrant#18YesStatus Tracking Database234Proceed to next pageSubmit to CustomerImportant note:Phase 2 a

7、nd Phase 3 can happen concurrently if all Inputs and Outputs are satisfiedNoINPUTSReleased design#1,2,3 & 4Trained supplier production operatorsSub-supplier(s) material status from Tier-x RRJob 1 Location (final site & line)Quantity of parts required as defined by customer (default 300 conse

8、cutive parts)Production process including control plan, flow diagram instructions & Process parameters #5,6 & 7Production Tools, Facilities & Gauging#8,16 & 17EVENT:Conduct Run at RatePlanned production cycle times required to support Daily Production VolumeOutputs from the eventSTAT

9、US:Phase 0 CompletedImplement Corrective Action on InputWas the Pre-Launch Control Plan followed?Were the prescribed number of acceptable parts produced? Were the parts produced in the defined period?Did all operations meet their planned cycle time?YesYesYesYesNoNoNoNoAre the RunRate input requireme

10、nts in place for the production stream?YesSTARTNo Capacity Analysis WorksheetStatus Tracking Database14Proceed to next pageRequired InputsSubmit to CustomerNote: #x refers to the Element Number in PPAP 4th Edition that will assist in confirming requirementsSTATUS: Phase 1 Completed Continue Producti

11、on Part Approval Process (PPAP) using parts from Phase 0- Dimensional measurements #9- Material Tests #10- Statistical process package #11- Performance Tests #12- Appearance criteria #13- Sample parts #14- Master samples #15- Customer Specific Requirements#17- as defined by PPAPHave the PPAP element

12、s been satisfied?YesStatus Tracking Database1424Important note: For suppliers with only one production stream completion of Phase 1 & 2 occur at the same timeProceed to next pageReturn to Phase 0 for corrective actionNoSubmit to CustomerPhase 1 Warrant#18Phase 2 WarrantScheduled down time define

13、d (TPM, change over, Breaks etc.) Sub supplier material status from Tier-x Phase 3EVENT: Conduct Capacity Verification RunSTATUS:Phase 3 Completed Quantity required is customer DPV for one full dayAll personnel for all shifts, trained Are the CVR input requirements in place for all production stream

14、s?YesENDStatus Tracking DatabaseReturn to affected phase and start corrective action Phase 3 Warrant #18& Capacity Analysis Report Determine Root Cause & Plan Corrective Action Was the control plan followed& acceptable parts produced?Did the volume of acceptable parts produced meet or ex

15、ceed the requiredDPV?NoYesNo3Required InputsPhase 0Phase 1Phase 2Have Run-at-Rates (Phase 0) been conducted and Quality Verifications (Phase 1) been satisfied for ALL production streams?Copyright 2000-2004 Ford Motor Company. All rights reserved.Phase 0: Run-At-Rate （按节拍生产）StartReleased Design#1, 2,

16、 3, 4Trained supplier production operatorsSub-supplier(s) material status from Tier-X Run-at-RateQuantity of parts required as defined by customer (default 300 consecutive parts)Job 1 location (final site and line)Production process including control plan, flow diagram instructions, and Process Para

17、meters#5, 6, 7Production tools, facilities, and gauging#8, 16, 17Planned production cycle times required to support daily production volumeAre the Run-at-Rate input requirements in place for the production stream?Was the pre-launch Control Plan followed?Were the prescribed number of acceptable parts

18、 produced?Were the parts produced in the defined period?Did all operations meet their planned cycle time?Implement corrective action on inputEVENT: Conduct Run-at-RateSTATUS: Phase 0 CompleteCapacity AnalysisReportStatus Tracking Database41YESNONONONONOYESYESYESSubmitto customerOutputs from the even

19、tYESCopyright 2000-2004 Ford Motor Company. All rights reserved.Phase 1 Prerequisites (Phase 1的先决条件）In order to begin Phase 1, the following are required:要进入Phase 1，必须达到以下条件： Successful completion of Run-at-Rate (Phase 0) for at least one work stream 对至少一条生产线成功完成节拍生产 Capacity Analysis Report complet

20、ed for at least one Job1-intended production work stream 对至少一条生产线成功完成产能分析 Tier “X” successful completion of Phase 1 分供方完成了Phase 1 PPAP.Copyright 2000-2004 Ford Motor Company. All rights reserved.Phase 1: Quality Verification (质量验证）1Continue Production Part Approval Process (PPAP) using parts from Ph

21、ase 0 Dimensional measurements #9 Material tests #10 Statistical process package #11 Performance tests #12 Appearance criteria #13 Sample parts #14 Master samples #15 Customer-specific requirements #17 As defined by PPAPReturn toPhase 0 for corrective actionSTATUS: Phase 1 CompletePhase 1 Warrant #1

22、8Status Tracking Database42NOSubmitto customerYESHave the PPAP elements been satisfied?Important note: for suppliers with only one production stream, completion of Phase 1 & 2 occur at the same time.4What is required to get Phase 1 PSW approval?获得Phase1 PSW的条件Copyright 2000-2004 Ford Motor Compa

23、ny. All rights reserved.Input Requirements （Phase 2的先决条件） Phase 2 requires the following （Phase2需要以下条件）: All Job 1 intended production work streams have successfully completed Run-at-Rate （所有生产线都成功完成了节拍生产） Capacity Analysis Reports completed for all Job 1 intended production work streams （所有生产线都成功完成

24、了产能验证） Tier X successful completion of Phase 2 (分供方完成Phase 2 PPAP).Page 51 Define Tier X and include note requesting addl info for script due to soundCopyright 2000-2004 Ford Motor Company. All rights reserved.Phase 2: Production Verification （生产验证）2STATUS: Phase 2 CompletePhase 2 Warrant #18Status

25、Tracking Database3NOSubmitto customerYESHave Run-at-Rates (Phase 0_ been conducted and Quality Verifications (Phase 1) been satisfied for ALL streams?Important note: Phase 2 and Phase 3 can happen concurrently if all inputs and outputs are satisfied.4Copyright 2000-2004 Ford Motor Company. All right

26、s reserved.Phase 3: Capacity Verification3Are all personnel for all shifts trained?Quantity required is customer DPV for one full dayPhase 2 WarrantScheduled down-time defined (TPM, change-over, breaks, etc.)Sub-supplier material status from Tier X Phase 3Are the CVR input requirements in place for

27、all production streams?Was the production control plan followed and acceptable parts produced?Did the volume of acceptable parts meet or exceed the required DPV?Determine root cause and plan corrective actionEVENT: Conduct Capacity Verification RunSTATUS: Phase 3 CompletePhase 3 Warrant #18 & Ca

28、pacity AnalysisReportStatus Tracking DatabaseYESSubmitto customerOutputs from the eventNOEndReturn to affected phase and start corrective actionComplete Capacity Analysis WorksheetPhase 0Phase 1Phase 2Phase 3NONOYESYESFord Special Requirements to PPAP 18 Elements福特对生产件批准福特对生产件批准18个要素的要求个要素的要求1. Desi

29、gn Record 设计记录设计记录The design must be released and authorized by Ford D&R.总成图必须获得福特设计工程师的批准，并在福特系统中(WERS)发布。Where the design record is in electronic format, the organization shall produce a hard copy (e.g., GD&T drawing) to identify measurements taken.当设计记录(如CAD/CAM数模、零件图纸、技术规范)是以电子格式（如数模）存在时

30、，供应商必须复制一份硬拷贝（如示意图、几何尺寸和公差表、图纸）以标识测量的内容。 Engineering change level properly indicates the latest design change.工程变更等级必须符合最新的设计变更状态For FSS, if the parts are identified as black box, the design record should at least specifies the interface and performance requirements. (e.g. Vehicle Assembly Position)

31、.对全服务供应商，对于定义为黑盒子的零件，设计记录要规定和其他件配合的关系和性能要求。2. Engineering Change Documents 工程变更文件工程变更文件SREA signed by CFT. 供应商工程变更申请WERS Concern. - 如果有权限进入WERS，供应商可以通过WERS Concern来提交设计变更 - 福特提出的设计变更通过WERS Concern来通知供应商和内部相关人员WERS = World Engineering Release System3. Customer Engineering Approval 客户工程批准客户工程批准The org

32、anization shall obtain documented Ford Product Development engineering approval of DV (Design Verification) and PV (Production Validation) tests of the initial sample parts. 供应商必须获得福特PD部门对D/PVP&R的书面批准。The organization shall conduct the PV testing on parts/products which were produced at “run at

33、rate”. （使用节拍生产出来的零件进行PV试验）Where appropriate, Ford Engineering records initial sample part approval on the ESER/ESO. 工程批准的方式可能有很多：ESER, ESO, DVP&RWERS Alert for Interim-Approval. 临时批准需要有WERS Alert支持。4. DFMEA 设计不良模式效应分析设计不良模式效应分析When developing FMEA, the requirements of Ford FMEA handbook (special

34、 characteristic definition) shall be met. 有产品设计职责的组织，必须按照福特的FMEA手册开发设计FMEA。For parts with YC/CC, DFMEAs must be approved in writting by Ford D&R engineer. 如果零件有关键特性（YC/CC,车辆安全规范或政府法规控制），DFMEA要获得福特设计工程师的书面确认。Ford reserves the right to review and approve all organization-developed DFMEAs. 福特保留审核和批

35、准供应商开发的DFMEA的权利。Over patent concerns, sometimes, supplier does not wanna share DFMEA, we could review it at the supplier site or have the supplier bring them to our office. （现场审核DFMEA硬拷贝）5. Process Flow Diagram 过程流程图过程流程图制造过程绘制制造过程绘制 Mapping the Manufacturing Process. 组队Organize the team 制作过程流程图Deve

36、lop A Process Flow Diagram 确定每一过程的偏差来源Identify sources of variation in each process 结合经验教训Incorporate lessons learned 记述各个步骤的目的Describe purpose of each step5. Process Flow Diagram 过程流程图过程流程图6. PFMEA 过程过程FMEAGeneral Procedure to develop PFMEA: 编制过程FMEA的一般流程Ask the questions: 哪些方面可能会出现错误？What can go w

37、rong? 如果发生了会怎样！产生什么影响？So what ! Effect ? 不产生功能No function产生部分功能Partial出现不需要的功能Unintended function 原因？Cause (s)?6. PFMEA 过程过程FMEAGeneral Procedure to develop PFMEA: 编制过程FMEA的一般流程(续)6. PFMEA 过程过程FMEAProcess FEMA Output 过程FEMA 输出： 哪些需要被控制What needs to be controlled 对于产品和过程来说哪些是关键的？ What is critical in

38、the product & the process 怎样来控制这些How to control these things 6. PFMEA 过程过程FMEAIf DFMEA does not exist, the team must have a meeting with the Design Engineer - using the CRT approach. 如果没有DFMEA，供应商需要和福特设计工程师确定关键特性和显著特性的清单。For parts with CC, PFMEAs need to get Ford Engineering & STA Approval.

39、对有关键特性的零件，PFMEA要获得福特PD和STA的批准。Characteristic traceability is required from the DFMEA through the PFMEA to the Control Plan (Supp.K). 要保证特殊特性在各个文件中的一致性。Error Proving list is one output of PFMEA. 防错清单是PFMEA的一个重要输出。PFMEA is living document. (8D, SREA) PFMEA要不断更新。7. Control Plan 控制计划控制计划 对过程按从开始到结束的逻辑顺序

40、Documenting the logical order of processes, start to finish 说明产品特性及过程参数Specify product characteristics and process parameters 对什么进行控制及怎样控制What to control & how 何时进行控制及控制程度When to control & how much 如遇故障，下步需做什么What to do, if all failed7. Control Plan 控制计划控制计划CC/SC list is properly cascaded in

41、 to CP. 控制计划要体现对特殊特性的有效控制。Incoming Inspection is the 1st part of CP. 来料检验是控制计划的第一部分。The Reaction Plan should be evaluated for effectiveness and use. 评估应变计划以验证其有效性Lists all process parameters and part characteristics that require specific quality planning actions. 对产品特性和过程特性都要规定有效的控制措施STA approval. S

42、TA批准（对CC件，要获得福特PD和STA批准）Living documentation. （根据变更和8D更新控制计划）7. Control Plan 控制计划控制计划 Potential Critical Characteristics andSignificant Characteristics Identified DFMEA DVP & R PFMEA DVP&R Pre- Launch Control Plan Production Control Plan Prototype Control Plan Modification of PFMEA (as requi

43、red) Standard Work Instructions/Visual Aids Process Flow Diagram Employee & Customer Safety Government Regulations Design Field Actions Warranty Customer Concerns Actual Critical Characteristics andSignificant Characteristics Identified 8. Measurement System Analysis 测量系统分析研究测量系统分析研究All gauges (

44、both general or dedicated) in Control Plan. 无论测量系统的类型是什么，用于检查福特产品的所有量具,都需进行量具再生/再现性分析。 MSA 3.0 based. 基于MSA3.0版本Associated % tolerance and % study variation. 在总偏差中的量具误差占公差的比例和过程变差的比例。To variable gages, the parts used for the Gauge R&R study must be within Design Record specifications. 对计数型量具，用于M

45、SA的零件必须符合设计规范。The acceptance criteria for Gauge R&R as a percent of TOLERANCE is less than 10%. If %tolerance is over 10% customer approval is needed. The Gauge is unacceptable if % tolerance is over 30%. NDC more than 5.ANOVA Method preferred with Minitab. （优先使用方差方法）Dimensional Measurements to

46、compare the actual part with the drawing (bubble prints). Default are 3 parts measured (5 pcs preferred). 比较实际零件是否符合设计记录的要求，默认三件。If production parts will be produced from more than one cavity, mold, tool, die, pattern or production process, a dimensional evaluation on one part from each should be co

47、mpleted. 对于每个独立加工的过程，如：生产单元或生产线，和所有的多模腔、成型模、模型或冲模，都必须有全尺寸测量结果。 Make one of the parts measured as Master Sample“. 将其中一个零件作为标准样品10. Material/Performance Test Results 材料材料/性能试验结果的记录性能试验结果的记录Where Ford specifies that materials are to be purchased from an approved supplier, the organization should contac

48、t the buyer to determine appropriate materials suppliers. 对特殊材料必须选择福特指定的供应商。Ford PD is supposed to approve the PV test plan, and to sign the PVP&R. PV试验计划要获得福特PD的确认。PV试验成功完成后，PD要在PVP&P上签字。All PV test requirements are clearly identified in the DVP&R. (PVP&R) D/PVP&R中必须规定试验设备。PV te

49、sting is supposed to use run at rate parts. PV试验的零件来自节拍生产All test equipment used for PV Testing is available and in the appropriate location (fully calibrated and certified). 试验设备要经过校准和确认。11. Initial Process Study 初始过程研究初始过程研究MSA should be conducted before Ppk study. 在进行初始过程研究之前，必须确保量具已经做过MSA。Ppk is

50、 required for Initial Process Study, SCs and CCs must meet at minimum 1,67 Ppk. 特殊特性要满足Ppk=1.67的要求。Focus on variables data. 针对计数性数据If Ppk =1.67的条件，必须采用防错或者100%检测来控制该特性。Cpk or Ppk?-Cpk is to determine if the process is capable to meet specifications, and is a prediction of what your process can do. -

51、The process has to be in statistical control. -At leat 100 individual samples available.when you cant determine statistical control or if you are looking at a very short production run, Ppk should be used.12. Qualified Lab Documentation 合格的实验室文件合格的实验室文件The qualified laboratory (internal or external)

52、 shall have a laboratory scope and documentation to show it is qualified to conducted the inspection and testing for PPAP. 组织必须有一份实验室范围和说明所使用的实验室遵循的证明文件。The external laboratory shall be in compliance with the latest ISO/IEC 17025 (or national equivalent). 外部实验室要符合最新ISO/IEC 17025的要求 （或所在国等同要求）13. App

53、earance Approval Report 外观批准报告外观批准报告All parts/products having appearance criteria shall be reviewed and approved by the appropriate Ford activity (Design Quality).当产品和零件在设计记录上有外观要求且要求提交时，则每一个零件或零件系列都必须填写一份单独的外观批准报告（AAR）。Appearance approval includes, but is not limited to: overall appearance, surface

54、 quality, color, texture, and gloss.外观批准包括整体外观，表面质量，颜色，皮纹和光泽度等等。Visual match-to-master is the specified requirement for AAR sign-off. Numeric evaluations should only be used for on-going quality control after visually acceptable parts/products are attained.AAR是福特精致工艺部门参照外观标准对零件的视觉比较（主观的）。计量型评价方法只可以作

55、为生产过程控制的方法来使用，但必须在获得AAR之后。AAR plan and Pre-AAR.14. Sample Production parts 生产件样品生产件样品Customer defines the quantity. 客户规定生产件样品的数量。Sample Parts are needed for the parts functioning in the Vehicle or Powertrain Assembly。生产件样品用来在整车厂或发动机厂作功能性装车试验。Photos as evidence is acceptable.可以使用照片作为证据。15. Master Sam

56、ple 标准样件标准样件Master sample which is retained in the suppliers site for reference. Master sample has the same life as PPAP package.标准样件由供应商负责保管，保存期与生产零件批准文件的保存期相同 。Supplier shall retain a master sample from each position of a multiple cavity die, mold, tool or partern, or production process unless oth

57、erwise sepcified by the customer.组织必须保存一份由多腔模具、铸模、工装、仿形模或生产过程的每一腔模具生产的样件。Customer (STA&PD) signature with approval date.标样必须标识顾客批准标样的日期。 Dimensional Result is required form Master Sample 标准样件要有全尺寸报告16. Checking Aids 检查辅具检查辅具Gauge strategy and drawing approved by customer.专用检具和特殊工装的图纸。检验辅具可以是零件专用

58、检具，包括卡具、量规、模形、模版及聚酯薄膜。The gauges are to the latest design level.检具必须符合零件的最新设计状态。MSA study to checking fixtures is required.对专用检具要做MSA分析。17. Customer Specific Requirements客户特殊要求客户特殊要求 -Packaging Approval 包装批准包装批准Expendable Package VS. Returnable Dunnage.一次性包装 VS. 可回收包装Forms: 表格 - FoE&FAP: FORM 11

59、21 (via FSBC) 福特欧洲和亚太：1121表 （福特澳洲通过FSBC提交） - NA: FORM 150E 福特北美：150E表Trial shipment that simulates the production logistics process. (Water Shipment Trial for exporting suppliers)如果使用福特指定的物流商，供应商需要完成海运试验来支持包装批准。17. Customer Specific Requirements- Capacity Verification （产能验证）（产能验证）Measure the ability of a supplier to meet Ford Motor Companys Capacity Planning Volume (CPV) with quality parts, on time.目的是验证供应商能否满足福特产能的要求。Capacity verification to each work station